Method and apparatus for producing a tubular sealing element

ABSTRACT

A method for producing of a tubular sealing element for sealing a safing slot in a curtain wall construction is described, particularly for sealing the slot with regard to noise, smoke, and fire and if applicable with regard to water, and an apparatus for producing such a tubular sealing element, as well as to the use of the tubular sealing element produced according to the invention for fire-, smoke-, sound- and water-proof sealing of perimeter joints in curtain wall constructions are described. In particular, an improved method for continuous and endless production of a tubular sealing element for different safing slot dimensions is described.

FIELD OF THE INVENTION

The present invention relates to a method for producing of a tubularsealing element for sealing a safing slot in a curtain wallconstruction, particularly for sealing the slot with regard to noise,smoke, and fire and if applicable with regard to water, to an apparatusfor producing such a tubular sealing element, as well as to the use ofthe tubular sealing element produced according to the invention forfire-, smoke-, sound- and water-proof sealing of perimeter joints incurtain wall constructions. In particular, the invention relates to animproved method for continuous and endless production of a tubularsealing element for different safing slot dimensions.

BACKGROUND OF THE INVENTION

Curtain walls are generally used and applied in modern buildingconstructions and are the outer covering of said constructions in whichthe outer walls are non-structural, but merely keep the weather out andthe occupants in. Curtain walls are usually made of a lightweightmaterial, reducing construction costs and weight. When glass is used asthe curtain wall, a great advantage is that natural light can penetratedeeper within the building.

A curtain wall generally transfers horizontal wind loads that areincident upon it to the main building structure through connections atfloors or columns of the building. Curtain walls are designed to resistair and water infiltration, sway induced by wind and seismic forcesacting on the building and its own dead load weight forces. Curtainwalls differ from store-front systems in that they are designed to spanmultiple floors, and take into consideration design requirements such asthermal expansion and contraction, building sway and movement, waterdiversion, and thermal efficiency for cost-effective heating, cooling,and lighting in the building.

There are different types of curtain wall structures, e.g. curtain wallstructures having a common curtain wall design including a foil-facedcurtain wall insulation, a steel back pan design or which include glass,especially vision glass extending to the finished floor level below.

A typical curtain wall configuration comprises a profiled framework ofvertical studs, so called mullions, and horizontal studs, so calledtransoms. The space between these profiles is either filled with glasspanels within the window area or spandrel panels within the front of thefloors. A common spandrel design comprises a pre-manufactured metal panfilled with insulating material. The remaining gap between spandrel andfloor has to be sealed against fire, smoke and sound and withstandcertain movement.

Curtain wall structures including an interior panel such as a back panor other similar construction which can be of metal or other materialextending across the interior surface of a curtain wall are common inmodular designs. The interior panels of a curtain wall are generallymade from a metal or insulation material which can easily bend, distortor be otherwise deformed when exposed to strong winds or elevatedtemperatures, such as intensive sunlight or heat, such as in the eventof a fire. Bending, distorting or deforming of these interior panels canresult in significant problems in attempting to maintain a completethermal insulation and seal within the safing slots between the outeredges of the floor construction and the exterior curtain wallconstruction during a storm or fire. In particular, maintaining of acomplete thermal insulation and seal at all time during a fire isimportant to prevent heat, smoke and flames from spreading from onefloor to an adjacent floor. Further, it is important to prevent waterinfiltration as well as to inhibit water transfer within the buildingstructures and to enhance water-tightness of the safing slot sealingsystem, i.e. in general it is important to enhance the water-stoppingproperties of the insulation and seal within the safing slot.

The gap between the floor and the interior wall surface of a curtainwall defines a safing slot, also referred to as perimeter slab edge(void) or perimeter joint, extending between the interior wall surfaceof the curtain wall construction and the outer edge of the floor. Thissafing slot is essential to slow the passage of fire and combustiongases between floors. Therefore, it is of great importance to improvefire stopping at the safing slot in order to keep heat, smoke and flamesfrom spreading from one floor to an adjacent floor. It is important tonote that the firestop at the perimeter slab edge is considered acontinuation of the fire-resistance-rating of the floor slab.

In order to obtain certified materials, systems and assemblies used forstructural fire-resistance and separation of adjacent spaces tosafeguard against the spread of fire and smoke within a building and thespread of fire to or from the building, the International Building CodeIBC 2012 provides minimum requirements to safeguard the public health,safety and general welfare of the occupants of new and existingbuildings and structures. According to the International Building CodeIBC 2012 Section 715.4, voids created at the intersection of theexterior curtain wall assemblies and such floor assemblies shall besealed with an approved system to prevent the interior spread of firewhere fire-resistance-rated floor or floor/ceiling assemblies arerequired. Such systems shall be securely installed and tested inaccordance with ASTM E 2307 to provide an F-rating for a time period atleast equal to the fire-resistance-rating of the floor assembly.

There are very few complicated curtain wall systems known that complywith the requirements according to ASTM Designation: E 1399-97(Reapproved 2005), in particular having a movement classification ofclass IV. Class IV is a combination of thermal, wind, sway and seismicmovement types. These have been tested according to the invention inboth horizontal and vertical conditions. The E 1399, Standard TestMethod for Cyclic Movement and Measuring the Minimum and Maximum JointWidths of Architectural Joint Systems, is used for simulation ofmovements of the ground, such as for example an earthquake, or evenmovements under high wind load or life load.

However, there is no fire-, smoke-, sound- and water-proof system knownthat is used in a curtain wall structure that meets above criteria.Additionally, there are a lot of sealing systems known that use onlymineral wool for isolating purposes. However, mineral wool itself is notwatertight and has to be coated or otherwise impregnated beforeemploying it within a safing slot of a curtain wall structure to preventwater infiltration as well as to inhibit water transfer within thebuilding structures and to enhance water-tightness of the safing slotsealing system. Therefore, there is a need for alternative safing slotfilling system, which addresses the above and enhances thewater-stopping properties of the insulation and seal within the safingslot and which can be produced cost-effective, and continuous.

Different methods for producing tubular sealing elements, such asprofile strands and joint cores, for sealing building joints,particularly connection joints, with regard to noise and smoke are knownfrom the state of the art, such as for example from DE 3038524 A1 andU.S. Pat. No. 2,898,634. DE 102010008570 A1 describes a method forproducing a fire-protection joint cord, wherein an intumescent foamflows into a tube and is caused to foam there. Disadvantages in DE102010008570 A1 are the predetermined diameter of the tube, as well as abackup of the material mass that might occur during the productionprocess or insufficient material mass in the joint cord that isproduced.

The systems of the state of the art relate to processes for jointproductions for use within drywall constructions, but nor within curtainwall constructions. These processes have additional disadvantages suchas, for example, significant time expenditure during production due tocomplicated cleaning steps of the system or due to complicatedrefitting, high costs, structure of the joint core or of the tubularsealing element composed of multiple components or complicatedconstruction elements, poor ability to be cut, great weight or veryinconvenient installation for building joints, particularly forconnection joints.

It is therefore an object of the invention to provide a method forproducing a tubular sealing element for sealing a safing slot within abuilding construction having a curtain wall construction defined by aninterior wall surface including at least one vertical and at least onehorizontal framing member and at least one floor spatially disposed fromthe interior wall surface of the curtain wall construction defining thesafing slot extending between the interior wall surface of the curtainwall construction and an outer edge of the floor, particularly forsealing them with regard to noise, fire and smoke, and, if applicable,with regard to water, which method avoids the disadvantages of the knownmethods. In particular, it is an object of the present invention toprovide an improved method for continuous and endless production of sucha tubular sealing element for different safing slot dimensions.

It is a further object of the present invention to provide an apparatusthat allows cost-advantageous, economical, continuous and endlessproduction of such a tubular sealing element.

It is a further object of the present invention to provide use of thetubular sealing element produced according to the invention foracoustical, smoke-proof fire-proof and/or water-proof sealing.

These and other objects that are evident from the following descriptionof the invention are accomplished by the present invention as it isdescribed in the independent claims. The dependent claims relate topreferred embodiments.

SUMMARY OF THE INVENTION

The present invention relates to a method for producing a tubularsealing element for sealing a safing slot in a curtain wallconstruction, comprising the following steps:

a) providing a first film on a conveyor belt,

b) applying a reaction mixture capable of flow on a top side of thefirst film,

c) providing a second film over the applied reaction mixture and over afirst and a second side edge region of the first film,

d) connecting a first side edge region of the second film with the firstside edge region of the first film, and connecting a second side edgeregion of the second film with the second side edge region of the firstfilm, to produce an essentially cylindrical tubular sealing element witha first and a second connection area,wherein the volume of the reaction mixture capable of flow to be appliedis metered in such a manner that it corresponds to the inside volume ofthe tubular sealing element produced, in the reacted state, andwherein parts of the first film and parts of the second film completelyenclose the reaction mixture.

The present invention furthermore relates to an apparatus for producinga tubular sealing element, for sealing a sating slot in a curtain wallconstruction, having a casting system for mixing and applying a reactionmixture capable of flow, comprising

a) a first feed apparatus for supplying a first film,

b) a second feed apparatus for supplying a second film,

c) at least one conveying means for laying the first and second filmflat and conveying it,

d) a shaping shoulder for shaping the first film,

e) a metering system for applying a reaction mixture capable of flow,

f) a thermal welding system for connecting a first side edge region ofthe second film with the first side edge region of the first film, andconnecting a second side edge region of the second film with the secondside edge region of the first film,

g) a reaction segment for allowing the reaction mixture capable of flowto foam, and

h) conveying technology for precise guidance of the films.

Furthermore, the present invention relates to use of the tubular sealingelement produced according to the invention for fire-, smoke-, sound-and water-proof sealing of perimeter joints in curtain wallconstructions.

Other objects and characteristics of this invention are obvious, inpart, and are explained hereinafter, in part.

BRIEF DESCRIPTION OF THE FIGURES

The subject matter of the present invention is further described in moredetail by reference to the following figures:

FIG. 1 shows a side cross-sectional view of an embodiment of the tubularsealing element produced according to the present invention arrangedbetween the outer edge of a floor and the interior wall surface of thecurtain wall construction, when initially installed and attached to ahorizontal framing member (transom at floor level, i.e. zero spandrel)in a curtain wall construction, wherein the vision glass extends to thefinished floor level below.

FIG. 2 shows an embodiment of the method and apparatus for production ofa tubular sealing element.

FIG. 3 shows an embodiment of the method for production of a tubularsealing element.

DETAILED DESCRIPTION OF THE INVENTION

The following terms were used within the scope of the present invention:

The term “curtain wall structure” or “curtain wall construction” incontext with the present invention refers to a wall structure defined byan interior wall surface including one or more framing members and atleast one floor spatially disposed from the interior wall surface of thecurtain wall construction. In particular, this refers to curtain a wallstructure having a common curtain wall design including foil-facedcurtain wall insulation, a steel back pan design or which includesglass, especially vision glass extending to the finished floor levelbelow.

The term “safing slot” in context with the present invention refers tothe gap between a floor and the interior wall surface of the curtainwall construction as defined above; it is also referred to as “perimeterslab edge” or “perimeter joint”, extending between the interior wallsurface of the curtain wall construction and the outer edge of thefloor.

The term “interior wall surface” in context with the present inventionrefers to the inner facing surface of the curtain wall construction asdefined above, for example to the inner facing surface of the infilledvision glass and the inner facing surface of the framing members.

The term “connection area”, also considered as an “attachment area”, incontext with the present invention refers to from the main body of thetubular sealing element outwardly projecting flexible wings or tabs,which constitute of parts of the bottom side cover and the top sidecover (wing-like), which surround the foam material (main body). Theconnection areas are preferably positioned at upper corners of the mainbody in an area where the bottom side cover is connected to the top sidecover.

The term “enhancing water-stopping properties” in context with thepresent invention refers to the prevention of water infiltration as wellas to inhibition of water transfer within the building structures and toenhancing water-tightness of the safing slot sealing system.

The term “intumescence” within the scope of the present invention means,in this regard, that the material expands under the effect of heat, forexample in the event of a fire, and forms an insulating layer composedof flame-retardant material, in other words it intumesces.

The terms “has/have,” “having,” and “has/have” are supposed to beinclusive and mean that other elements aside from those mentioned canalso be intended.

Used within the scope of the present invention, the singular forms “a”and “an” also include the corresponding plural forms, unless the contextclearly permits a different conclusion. Therefore the term “a,” forexample, is supposed to mean “one or more” or “at least one,” unlessindicated otherwise.

In one aspect, the present invention relates to a method for producing atubular sealing element for sealing a safing slot in a curtain wallconstruction, comprising the following steps:

a) providing a first film on a conveyor belt,

b) applying a reaction mixture capable of flow on a top side of thefirst film,

c) providing a second film over the applied reaction mixture and over afirst and a second side edge region of the first film,

d) connecting a first side edge region of the second film with the firstside edge region of the first film, and connecting a second side edgeregion of the second film with the second side edge region of the firstfilm, to produce an essentially cylindrical tubular sealing element witha first and a second connection area,wherein the volume of the reaction mixture capable of flow to be appliedis metered in such a manner that it corresponds to the inside volume ofthe tubular sealing element produced, in the reacted state, andwherein parts of the first film and parts of the second film completelyenclose the reaction mixture.

In a further aspect, the present invention relates to an apparatus forproducing a tubular sealing element, for sealing a safing slot in acurtain wall construction, having a casting system for mixing andapplying a reaction mixture capable of flow, comprising

a) a first feed apparatus for supplying a first film,

b) a second feed apparatus for supplying a second film,

c) at least one conveying means for laying the first and second filmflat and conveying it,

d) a shaping shoulder for shaping the first film,

e) a metering system for applying a reaction mixture capable of flow,

f) a thermal welding system for connecting a first side edge region ofthe second film with the first side edge region of the first film, andconnecting a second side edge region of the second film with the secondside edge region of the first film,

g) a reaction segment for allowing the reaction mixture capable of flowto foam, and

h) conveying technology for precise guidance of the films.

In yet another aspect, the present invention relates to use of thetubular sealing element produced according to the invention for fire-,smoke-, sound- and water-proof sealing of perimeter joints in curtainwall constructions.

Such a tubular sealing element is described in detail in Ser. No.16/353,434, which is incorporated here by making reference to it.

It has been found that the method according to the invention isparticularly suitable for producing a tubular sealing element in asimple, continuous, economical and cost-advantageous manner, in order toreliably seal sealing a safing slot in a curtain wall construction,particularly with regard to noise, smoke, and fire and if applicablewith regard to water. In particular, the tubular sealing elementproduced according to the invention can be easily produced withdifferent widths with regard to the cross-sectional form, forapplication in different safing slot widths by minor modifications ofthe production line.

Therefore, it is an objective of the present invention to describe themethod for producing a tubular sealing element for sealing a safing slotin a curtain wall construction. Furthermore, it is an objective of thepresent invention to describe the apparatus for producing a tubularsealing element, for sealing a safing slot in a curtain wallconstruction, in detail. Furthermore, it is an objective of the presentinvention to describe use of the tubular sealing element producedaccording to the invention for fire-, smoke-, sound- and water-proofsealing of perimeter joints in curtain wall constructions.

Such a tubular sealing element can be produced, according to theinvention, in that a suitable reaction mixture capable of flow isapplied to a first film, of which a first side edge region issubsequently connected with a first side edge region of a providedsecond film, and of which a second side edge region is subsequentlyconnected with a second side edge region of the provided second film, toproduce an essentially cylindrical tubular sealing element, wherein thefoaming, deformable material passes through a reaction segment, togetherwith the films, and is formed into a tubular sealing element with afirst and a second connection area.

For this reason, the method according to the invention, for producing atubular sealing element for sealing a building joint, comprises thefollowing steps:

a) providing a first film on a conveyor belt,

b) applying a reaction mixture capable of flow on a top side of thefirst film,

c) providing a second film over the applied reaction mixture and over afirst and a second side edge region of the first film,

d) connecting a first side edge region of the second film with the firstside edge region of the first film, and connecting a second side edgeregion of the second film with the second side edge region of the firstfilm, to produce an essentially cylindrical tubular sealing element witha first and a second connection area,wherein the volume of the reaction mixture capable of flow to be appliedis metered in such a manner that it corresponds to the inside volume ofthe tubular sealing element produced, in the reacted state, andwherein parts of the first film and parts of the second film completelyenclose the reaction mixture.

Furthermore, the method according to the invention comprises the steps:

e) optionally perforating the tubular sealing element,

f) allowing the reaction mixture capable of flow to foam, therebyshaping the desired profile geometry,

g) venting the tubular sealing element, and

h) cutting the tubular sealing element to the desired length.

Furthermore, the method according to the invention comprises theadditionally steps of:

i) applying an adhesive layer,

j) optionally creating openings or perforations for water transfer, and

k) optionally welding the outer sides of the connection areas to achievecomplete water-tightness.

According to the invention, in a first step of the method, making afirst film available takes place by means of a feed apparatus, which maycomprise at least one roller, by way of which the first film is suppliedfrom a film supply of a rotating roll. At this step it is optional toperforate the film for venting.

It is practical if the first film provided is a bottom side cover, suchas a bottom side laminate. This laminate may comprise at least twolayers, preferably comprises three layers. In particular, the bottomside laminate comprises a plastic foil layer, preferably comprisingpolyethylene, polypropylene or the like, wherein a mesh layer islaminated between the plastic foil layers, most preferably between twopolyethylene foil layers. In a most preferred embodiment, the bottomside laminate is a laminate having a glass fibre mesh layer laminatedbetween two polyethylene layers. Alternatively, the bottom side covermay also consist of one or more layers, such as layers or reinforcedlayers from a woven material, a woven fabric, a foil, a reinforced fiberfabric or the like, or a combination therefrom. The material of the filmis preferably a laminate material that does not enter into any adhesionconnections with the foam system. When producing the tubular sealingelement the film material foaming in the film sheath can also take placein a support mold, which determines the outer contour of the film, whichexpands during the foaming process.

In a next step of the method according to the invention, the film islaid onto a conveying means, preferably a conveyor belt or beltconveyor, and passed over a shaping shoulder where the side edge regionsof the film are set slightly upright, so that the reaction mixturecapable of flow can be applied in a next step.

According to the invention, a deformable reaction mixture capable offlow is used in the method. In this regard, the material can be eitherplastically or elastically deformable. Preferably, the deformablereaction mixture capable of flow is a polyethylene mixture, apolyurethane mixture or a cellular rubber mixture. In particular, thefinished tubular sealing element consists of a material that is capableof recovery after compression, such as, for example, foam material, foamrubber, cellular rubber or the like. Possible foam materials that can bementioned are usual foam materials such as polyethylene foam materialand polyurethane foam material or cellular rubber. In this regard, thefoam material can be an open-cell foam material with very low airpassage resistance, also an almost closed-cell foam material withextremely low air passage values. Foam materials having air passagevalues that lie between the two extreme cases mentioned above can alsobe used within the scope of the present invention. It is particularlypreferred that the reaction mixture capable of flow is a polyurethanemixture, most preferably an intumescent, open-celled foam material basedon polyurethane.

It has proven to be advantageous if the tubular sealing element producedaccording to the method according to the invention consists of aslow-burning foam material, such as, for example, cellular rubber orpolyurethane foam, which is sheathed with a film. In the case of aslow-burning foam material, there is no possibility of fire spreadingthrough the foam material. Independent ignition is excluded in the caseof the aforementioned foam materials as starting materials. It isadvantageous that in the event of a fire, dripping also does not takeplace. In a temperature range between 500° C. to 800° C., a slow-burningfoam material should still possess at least 20%, at least 25%,preferably still at least 30%, between 20% to 60%, between 20% to 40%,preferably between 25% to 30% of its initial volume. Furthermore, in atemperature range between 500° C. to 800° C., a slow-burning foammaterial should still possess at least 10%, at least 20%, preferablystill at least 30%, between 10% to 40%, between 10% to 30%, preferablybetween 15% to 20% of its initial mass.

Furthermore, the deformable reaction mixture capable of flow can containcorresponding additives if fire-protection properties, such asintumescence, for example, are desired. Under the effect of heat, as inthe event of a fire, the material inflates and forms an insulating layercomposed of material having low flammability. The formation of avoluminous insulating layer, namely an ash layer, can occur as theresult of the chemical reaction of a mixture composed of correspondingcompounds coordinated with one another, which react with one anotherunder the effect of heat. Such systems are known to a person skilled inthe art under the term chemical intumescence, and can be used accordingto the invention. Alternatively, the voluminous insulating layer can beformed by means of inflation of a single compound, which releases gaseswithout a chemical reaction between two compounds having taken place,under the effect of heat. Such systems are known to a person skilled inthe art under the term physical intumescence and can also be usedaccording to the invention. The two systems can be used alone ortogether, in each instance, as a combination, according to theinvention.

In a most preferred embodiment of the method of the present invention,the reaction mixture capable of flow is an intumescent, open-celled foammaterial comprising fire-protective additives having improvedhydrophobic properties. Preferably, the intumescent, open-celled foammaterial, is a foam material based on polyurethane. It is preferred,that the thermally resistant flexible foam material has a density inuncompressed state of 90 kg/m³.

The reaction mixture capable of flow can be mixed in an upstream mixingprocess, for example in a system that is suitable for applying thereaction mixture capable of flow, such as a casting system.

According to the invention, application of the reaction mixture capableof flow takes place by means of uniform orthogonal metering relative toa top side of the film. In particular, it is required, in the productionof the tubular sealing element according to the invention, that thereaction mixture capable of flow is metered uniformly orthogonal to thetop side of the open film. As a result, backup during the productionprocess that occurs in the material mass in a tube that has already beenfabricated, or insufficient material mass in the joint cord that isproduced are prevented. Preferably, the volume of the reaction mixturecapable of flow that is to be applied is metered in such a manner thatit corresponds to the inside volume of the tubular sealing elementproduced, in the cured state.

According to the invention, in a next step of the method, making asecond film available takes place by means of a feed apparatus, whichmay comprise at least one roller, by way of which the second film issupplied from a film supply of a rotating roll.

It is practical if the second film provided is a top side cover, such asa top side laminate. This laminate may comprise at least two layers,preferably comprises three layers. In particular, the top side laminatecomprises an aluminum layer, a plastic foil layer, preferably comprisingpolyethylene, polypropylene or the like, and a mesh layer. Mostpreferably, the top side laminate is constituted of a reinforcedaluminum layer with a polyethylene backing. Alternatively, the topsidecover may also consist of one or more layers, such as layers orreinforced layers from a woven material, a woven fabric, a foil, areinforced fiber fabric or the like, or a combination therefrom.

The bottom side cover and the top side cover can be of different or ofthe same materials depending on the material properties and intendedfunction. However, it is preferred that the bottom side cover and thetop side cover are of different materials.

In a particular preferred embodiment of the tubular sealing element, themesh layer of the bottom side laminate and/or the mesh layer of the topside laminate is made of a glass fiber material or a ceramic fibermaterial. The fiber mesh is used to retain the foam material in placeand enhance stability of the system as well as stabilizes the seal oncethe thermally resistant flexible foam material has been in contact withfire. The mesh layer of the bottom side laminate and/or the mesh layerof the top side laminate can be laminated between two layers ofcombustible foil for instance. Further, the mesh layer might be fixed orunfixed. Preferably, the mesh size of the mesh layer of the top sidelaminate differs from the mesh size of the mesh layer of the bottom sidelaminate. Preferably, the mesh sizes range in between of about 2 mm×2 mmto about 10 mm×10 mm, more preferably are about 5 mm×5 mm.

The second film is provided over the applied reaction mixture and over afirst and a second side edge region of the first film.

In a next step of the method connection of the films takes place andenchasing the reaction mixture by the films. In particular, the methodcomprises the step of connecting a first side edge region of the secondfilm with the first side edge region of the first film, and connecting asecond side edge region of the second film with the second side edgeregion of the first film, to produce an essentially cylindrical tubularsealing element with a first and a second connection area, wherein thevolume of the reaction mixture capable of flow to be applied is meteredin such a manner that it corresponds to the inside volume of the tubularsealing element produced, in the reacted state, and wherein parts of thefirst film and parts of the second film completely enclose the reactionmixture.

Preferably, the filled films are passed to a welding system, usingconveying technology, where connecting takes place by means of thermalwelding, with the formation of a fish fin weld seam. In this regard, thefilms should completely enclose the reaction mixture.

This tubular sealing element, formed in this way, is subsequently passedover a reaction segment by means of conveying technology, in whichsegment foaming of the reaction mixture capable of flow takes place.Preferably, foaming of the reaction mixture capable of flow takes placeover a time period of 15 to 90 seconds. In a particular embodiment ofthe method of the present invention, the conveying technology comprisesa conveyor belt or a belt conveyer having guide elements, for examplenubs or depressions, for precise guidance of the films.

During guidance over the reaction segment, shaping of the desiredprofile geometry can take place, if applicable. Preferably, the desiredprofile geometry can be formed by means of at least one conveyor belt orprofile.

According to the method, the cross-sectional form of the tubular sealingelement is generally of rectangular, trapezoidal, circular shape orU-shaped. Preferably, the cross-sectional form of the tubular sealingelement is rectangular shaped. The tubular sealing element can easily beproduced with different widths with regard to the cross-sectional form,for application in different safing slot widths in a curtain wallconstruction, for example the tubular sealing element can be produced ina width of about 3.54 inches (about 90 mm) that is used for a safingslot width of 1.5 inches to 3 inches (38.1 mm-76.2 mm), a width of about4.53 inches (about 115 mm) that is used for a safing slot width of 2inches to 4 inches (50.8 mm to 101.6 mm), and further a width of about5.55 inches (about 141 mm) that is used for a safing slot width of 3inches to 5 inches (76.2 mm to 127 mm) by adaptation of the conveyingmeans. These different sizes ease installation in that that the tubularsealing element does not need to be force-compressed into the safingslot. In an alternative embodiment with the tubular sealing elementhaving a generally trapezoidal cross-sectional shape, a larger side ofthe tubular sealing element can be positioned on the curtain wall sideand a smaller side of the tubular sealing element might be positioned onthe floor side. For example, the tubular sealing element might have athickness of 3.5 inches on the curtain wall side and a thickness of2.375 inches on the floor side thereby enhancing fire-stopping. Anyother dimensions for a trapezoidal shape are also feasible.

Subsequently, ventilation of the tubular sealing element takes place.This venting can take place by either perforation of the films by meansof a perforation unit or by venting the element via the connection areasbefore welding, in order to allow the reaction gases to escape and thepressure that has built up to dissipate. This ventilation prevents thefilm mantle from coming loose from the foam and inflating. Ventilationcan also take place by means of pricking small openings into the film,for example using a needle or needle roll, or by means of slit punchingor hole punching. Preferably, perforation of the film takes place bymeans of a rotating roll having applied needles. It is also possible toperforate the tubular sealing element at a later production step again,to accelerate exit of the resulting gases, which are predominantly CO₂.This reopening has the consequence that the gases do not have to bleedslowly through the foam via the small first perforations that serve forventing in the first process step, but can quickly exit, and anuncontrolled/unintentional inflation or detachment of the film whenleaving the reaction segment is avoided. Hereby, the process time issignificantly shortened. Venting of the tubular sealing element allowsambient air enclosed in the film tube and reaction gases that occurduring the foaming reaction of the reaction mixture capable of flow toescape, and thereby prevents gas inclusions that can cause bubbleformation within the tubular sealing element or under the film. By meansof perforation and thereby the possibility of gas escape, uniformshaping is ensured.

Furthermore, the method can also comprise the step of applying anadhesive layer to the tubular sealing element, if desired. Applicationof the adhesive layer is preferably performed by an adhesive feedapparatus, such as a hot-melt adhesive gun. In a preferred embodiment,the adhesive layer is positioned at the first connection area and/or thesecond connection area, wherein the adhesive layer may be positioned onan upper or on a lower side of the connection areas. Most preferred theadhesive layer is applied on the lower side of the connection areas. Itis preferred, that the adhesive layer is a hot-melt adhesive, a butylsealing, a double sided adhesive or a self-adhesive layer. In apreferred embodiment, the adhesive layer applied, including an adhesivebacker, is a hot-melt self-adhesive layer. In a most preferredembodiment, the adhesive baker is a silicone paper.

Furthermore, the method can also comprise the step of creating openingsor perforations for water transfer into the second film. Creation ofthese openings or perforations can be performed by pricking smallopenings into the film, by applying a laser, by perforating with aneedle, slit punching or hole punching, cutting or the like. In apreferred embodiment, openings or perforations are created on a bottomside cover of the tubular sealing element for water transfer from aninner side of the tubular sealing element to the outside in case wherewater has been infiltrated into the building structures and hence intothe sealing element, whereas the top side cover preferably does notcontain perforations or openings to prevent water entry from the topside by for example rain. In an alternative embodiment, the outersurface of the top side cover is convex.

Furthermore, the method can also comprise the step of welding the outersides of the connection areas to achieve complete water-tightness ifdesired.

In conclusion, the finished tubular sealing element is passed to acutting unit, if applicable, where cutting the tubular sealing elementto the desired length takes place, if continuous production is notdesired. Cutting preferably is performed by a cutter that issynchronized with the production/belt speed. Thus, no deformation andcompression of the product is necessary. The cut is preferably carriedout by means of a discus blade sitting on a planetary gear.Synchronously with the cut and product, a moving kerf is created in theunderlying belt by deflecting the belt by preferably three rollers.These three rollers are optimally synchronized mechanically with thecutter, possibly also via separate axes.

The method according to the invention thereby allows cost-advantageous,economical, continuous and endless production of tubular sealingelements. The method according to the invention is preferably carriedout by means of an apparatus for producing such tubular sealingelements.

In the embodiment of the method and apparatus for production of atubular sealing element 21 shown in FIG. 2, a film is passed from a feedapparatus, comprising at least one roller 24, by way of which the firstfilm is supplied from a film supply 23 of a rotating roll. In a nextstep, the film is laid onto a conveying means 25 and passed over ashaping shoulder 26 where the side edge regions of the film are setslightly upright. The reaction mixture is mixed in an upstream mixingprocess, for example in a system that is suitable for applying thereaction mixture capable of flow, such as a casting system 22.Application of the reaction mixture capable of flow takes place by meansof uniform orthogonal metering relative to a top side of the film. Asecond film is then made available from a second feed apparatus 27. Thefirst and second film are then connected with a thermal welding system28. This tubular sealing element, formed in this way, is subsequentlypassed over a reaction segment 29 by means of conveying technology 30.The desired profile geometry can be formed by means of at least oneconveyor belt or profile 31. Subsequently, ventilation of the tubularsealing element takes place by perforation of the films by means of aperforation unit 32. An adhesive layer is then applied to a lower sideof the connection area of the tubular sealing element by an adhesivefeed apparatus 33. Finally, the finished tubular sealing element ispassed to a cutting unit 34.

The embodiment of the method as shown in FIG. 3 first involves 210providing a first film on a conveyor belt. Then, in 211, a reactionmixture is applied to a top side of the first film. In 212, a secondfilm is provided over the applied reaction mixture and over the firstfilm. Then, 213 involves connecting first side edge regions of the firstand second films, and connecting second side edge regions of the firstand second films.

Such an apparatus for producing a tubular sealing element, for sealing asafing slot in a curtain wall construction, having a casting system formixing and applying a reaction mixture capable of flow, comprising

a) a first feed apparatus for supplying a first film,

b) a second feed apparatus for supplying a second film,

c) at least one conveying means for laying the first and second filmflat and conveying it,

d) a shaping shoulder for shaping the first film,

e) a metering system for applying a reaction mixture capable of flow,

f) a welding system for connecting a first side edge region of thesecond film with the first side edge region of the first film, andconnecting a second side edge region of the second film with the secondside edge region of the first film,

g) a reaction segment for allowing the reaction mixture capable of flowto foam, and

h) conveying technology for precise guidance of the films.

Preferably, the first feed apparatus for supplying the first filmcomprises at least one roller. Further preferably, the conveyingtechnology for precise guidance of the film comprises a conveyor belt orbelt conveyor having guide elements. Preferably, the conveyor belt orprofile for shaping the desired profile geometry can be given anydesired shape, or any desired shape can be produced by the conveyor beltor profile, and thereby the profile geometry of the tubular sealingelement can be predetermined.

Furthermore, the apparatus comprises a second feed apparatus forsupplying a second film in form of a roller.

The conveying technology encompasses at least one conveyor belt orprofile for shaping the desired profile geometry as well as means forprecise guidance of the films such as rollers, nubs and the like.

The apparatus according to the present invention, may further comprise

i) at least one perforation unit for venting the tubular sealingelement,

j) an adhesive feed apparatus,

k) optionally an unit for creating openings or perforations for watertransfer,

l) optionally welding the outer sides of the connection areas to achievecomplete water-tightness, and

m) a cutting unit for cutting the tubular sealing element to the desiredlength.

A particular embodiment of the tubular sealing element producedaccording to the invention, comprises a thermally resistant flexiblefoam material for insulating and sealing, the tubular sealing element isfor positioning in the safing slot, wherein the tubular sealing elementincludes a bottom side cover, a top side cover whereby the top sidecover is connected at two positions, spatially disposed from each other,to the bottom side cover and whereby the bottom side cover and the topside cover surround the thermally resistant flexible foam material; afirst connection area for attaching the tubular sealing element to theinterior wall surface of the curtain wall construction; and a secondconnection area for attaching the tubular sealing element to the outeredge of the floor. Preferably, the tubular sealing element producedaccording to the invention is used for sealing a safing slot in acurtain wall construction, particularly for sealing the slot with regardto noise, smoke, and fire and if applicable with regard to water. Such atubular sealing element is described in detail in Ser. No. 16/353,434,which is incorporated here by making reference to it.

The dimension and profile geometry as well as the materials of thetubular sealing element produced according to the invention are selectedin accordance with the planned use of the tubular sealing element andcan easily be implemented by means of the method according to theinvention.

Positioning of the tubular sealing element produced according to theinvention on one or more components can take place in one step. Suchinstallation of the tubular sealing element produced according to thepresent invention within a curtain wall construction, is described indetail in Ser. No. 16/353,856, which is incorporated here by makingreference to it.

Without restricting the scope of protection of the invention, theinvention will be described in greater detail using the FIG. 1, whichshows a side cross-sectional view of an embodiment of the tubularsealing element produced according to the present invention arrangedbetween the outer edge of a floor and the interior wall surface of thecurtain wall construction, when initially installed and attached to ahorizontal framing member (transom at floor level, i.e. zero spandrel)in a curtain wall construction, wherein the vision glass extends to thefinished floor level below. In particular, the dynamic, thermallyinsulating and sealing system 100 is initially installed in the area ofa zero spandrel area of a glass curtain wall construction, defined by aninterior wall surface 1 including one or more framing members, i.e.,vertical framing member—mullion 2—and horizontal framing member—transom3—which is located at the floor level, and at least one floor 4spatially disposed from the interior wall surface 1 of the curtain wallconstruction defining a safing slot 5 extending between the interiorwall surface 1 of the curtain wall construction and an outer edge 6 ofthe floor 4. The framing members 2 and 3 are infilled with vision glass7 extending to the finished floor level below. The dynamic, thermallyinsulating and sealing system 100 of the present invention has a tubularsealing element 8 comprising a top side cover 9 and a bottom side cover10 which together surround a thermally resistant flexible foam material11. The foam material is an intumescent foam material on a polyurethanebase with a certain percentage of fire-protective additive materials,preferably blowing graphite. During an event of a fire, the intumescentmaterials will create an ash crust which will provide the fireprotective function. The foam composition can be adjusted i.e. density,firestop filler percentage, etc. so that the necessary fire protectivefunction is provided to the safing slot. Preferably, the tubular sealingelement 8 has an approximately rectangular cross section with an uppersurface 12, a lower surface 13 being arranged approximately in parallelto each other and a first side surface 14 and a second side surface 15being arranged approximately in parallel to each other. Preferably, thetop side cover 9 is a top side laminate 9, which builds the uppersurface 12, whereas the bottom side cover 10 preferably is a bottom sidelaminate 10, which builds the lower surface 13 and both side surfaces 14and 15. The thermally resistant flexible foam material 11 is enclosedfrom the top side cover 9 and the bottom side cover 10, wherein thethermally resistant flexible foam material 11 is connected to innersurfaces of the top side cover 9 and of the bottom side cover 10. Whenmounted, the first side surface 14 of the tubular sealing element 8 isadjacent to the outer edge 6 of the floor 4 and the second side surface15 is adjacent to the interior wall surface 1 of the curtain wallconstruction preferably adjacent to the insulation positioned in azero-spandrel area 17 of the curtain wall construction. The uppersurface 12 of the mounted tubular sealing element 8 is flush with theupper surface 18 of the floor 4. In the present embodiment the tubularsealing element 8 has a smaller height than the floor 4, wherein theheight of the tubular sealing element 8 is preferably about half of theheight of the floor 4. Not shown in FIG. 1 are the first connection areaand the second connection area as well as the applied adhesive layers.The adhesive layers are used to adhere the tubular sealing element tothe interior wall surface of the curtain wall construction and to theouter edge of the floor.

As is evident from what has been explained above, the method accordingto the invention is particularly suitable for producing a tubularsealing element fire-, smoke-, sound- and water-proof sealing ofperimeter joints in curtain wall constructions, in cost-advantageous,economical, continuous and endless manner.

The method according to the invention and the apparatus according to theinvention are particularly characterized by the following advantages ascompared with systems of the state of the art:

Because of the uniform orthogonal metering relative to the surface ofthe film, no contamination of possible process feed lines takes place,because the foam only comes into contact with the film and not withfurther components of the apparatus. Furthermore, the apparatus allowsrapid refitting to other dimensions and diameters of the desired tubularsealing element, for example by replacing the shaping shoulder andadjusting the film width as well as the desired length of the tubularsealing element, without complicated refitting. The method and theapparatus according to the invention allow the production of tubularsealing elements for different safing slot widths, for example thetubular sealing element can be produced in a width of about 3.54 inches(about 90 mm) that is used for a safing slot width of 1.5 inches to 3inches (38.1 mm-76.2 mm), a width of about 4.53 inches (about 115 mm)that is used for a safing slot width of 2 inches to 4 inches (50.8 mm to101.6 mm), and further a width of about 5.55 inches (about 141 mm) thatis used for a safing slot width of 3 inches to 5 inches (76.2 mm to 127mm). By means of the tubular sealing element produced according to theinvention, a product is made available for different safing slot sizesand applications, which product can furthermore be producedcost-advantageously in a production line.

By means of the flexible use of multiple conveyor belts or profiles,free geometrical configuration of the profile, depending on the desiredarea of use, can take place. The connection areas of the tubular sealingelement produced according to the invention simultaneously serve as aninstallation aid. This furthermore has the advantage that the tubularsealing element can be installed quickly, and that the foam is protectedby the surrounding films from splashing water and during installation.

Furthermore, the method and the apparatus according to the inventionprevent backup of the material mass from occurring in a tube that hasalready been pre-fabricated, during the production process, or preventinsufficient material mass in the safing slot. Furthermore, the mixingquality/homogeneity of the foam is also not influenced by either mixingor shaping.

As is evident from what has been explained above, the tubular sealingelement produced according to the invention is particularly suitable forreliably sealing a safing slot in a curtain wall construction,particularly for sealing the slot with regard to noise, smoke, and fireand if applicable with regard to water, in a simple manner.

Furthermore, it has been shown that excellent sealing can be achievedwith the tubular sealing element produced according to the invention,because good compressibility of the sealing regions is guaranteed by theselection of the sealing materials and/or the geometrical configuration,without any additional aids. The tubular sealing elements producedaccording to the invention also allow setting the correct distance fromthe floor to the curtain wall structure, without additional aids, inorder to achieve the aforementioned precompression, by means of asuitable selection of the sealing materials and/or the geometricalconfiguration, and in particular by choosing the right profile dimensionfor the corresponding safing slot.

With the tubular sealing element produced according to the invention, itcan also be ensured that sufficient material is installed to guaranteeexcellent sealing with maximal expansion absorption and fire-resistance,and that this is already accomplished by the selection of the sealingmaterials and/or geometrical configuration.

In view of the above, it is evident that the objects of the inventionare accomplished. Because various modifications of the method, theapparatus, the tubular sealing element produced according to theinvention, and its use, as described above can be made without deviatingfrom the scope of the invention, the intention is that all the objectscontained in the above description are interpreted as illustrations andnot in a restrictive sense.

The invention claimed is:
 1. A method for producing a tubular sealingelement for sealing a building joint, comprising: a) providing a firstfilm on a conveyor belt, b) applying a reaction mixture capable of flowon a top side of the first film, c) providing a second film over theapplied reaction mixture and over a first and a second side edge regionof the first film, d) connecting a first side edge region of the secondfilm with the first side edge region of the first film, and connecting asecond side edge region of the second film with the second side edgeregion of the first film, to produce an essentially cylindrical tubularsealing element with a first and a second connection area, wherein firstfilm and the second film have different lengths in cross section, thesecond film having a first side surface comprising a first area ofattachment and a second side surface comprising a second area ofattachment, the first area of attachment and the second area ofattachment to mount the tubular sealing element in the building joint,and f) shaping the profile geometry, wherein a sealing portion of theprofile geometry, in cross section, consits of one sealing region,wherein the method further comprises metering flow of the reactionmixture to have a volume that corresponds to an inside volume of thetubular sealing element, in a reacted state, and wherein parts of thefirst film and parts of the second film completely enclose the reactionmixture, and wherein the method does not comprise perforating the firstconnection area or the second connection area.
 2. The method accordingto claim 1, further comprising: e) optionally perforating the tubularsealing element, f) allowing the reaction mixture capable of flow tofoam, thereby shaping the desired profile geometry, g) venting thetubular sealing element, and h) cutting the tubular sealing element tothe desired length.
 3. The method according to claim 1, furthercomprising: i) applying an adhesive layer to connection areas of thetubular sealing element, and either j) optionally creating openings orperforations for water transfer, or k) optionally welding outer sides ofconnection areas of the tubular sealing element to enclose the reactionmixture and achieve complete water-tightness.
 4. The method according toclaim 1, wherein step d) comprises a connecting process using thermalwelding.
 5. The method according to claim 1, wherein the first filmand/or the second film comprise(s) a laminate.
 6. The method accordingto claim 1, wherein the reaction mixture capable of flow is anintumescent, open-celled foam material based on polyurethane.
 7. Themethod according to claim 3, wherein applying the adhesive layer in i)is performed using an adhesive feed apparatus.
 8. The method accordingto claim 3, wherein j) is performed and wherein creating openings orperforations in j) for water transfer is performed by applying a laser.9. The method according to claim 1, wherein the tubular sealing elementcomprises a thermally resistant flexible foam material for insulatingand sealing, wherein the tubular sealing element is sized forpositioning in a safing slot, wherein d) comprises forming the tubularsealing element to comprise a bottom side cover and a top side cover,with the top side cover connected at two positions, spatially disposedfrom each other, to the bottom side cover; wherein the method comprisesforming the bottom side cover and the top side cover to surround thethermally resistant flexible foam material; and wherein the methodcomprises forming the tubular sealing element to comprise a firstconnection area for attaching the tubular sealing element to an interiorwall surface of the curtain wall construction and a second connectionarea for attaching the tubular sealing element to an outer edge of thefloor in an installed state.
 10. The method according to claim 1,further comprising forming the tubular sealing element based on a) to d)to have a continuous length.
 11. An apparatus for producing a tubularsealing element, for sealing a safing slot in a curtain wallconstruction, having a casting system for mixing and applying a reactionmixture capable of flow, comprising a) a first feed apparatus forsupplying a first film, a) a second feed apparatus to supply a secondfilm, c) at least one conveyor to lay the first and second film flat andto convey the first and second film, d) a shaping shoulder for shapingthe first film, e) a metering system for applying a reaction mixturecapable of flow, f) a thermal welding system for connecting a first sideedge region of the second film with the first side edge region of thefirst film, and connecting a second side edge region of the second filmwith the second side edge region of the first film, g) a reactionsegment to foam the reaction mixture capable of flow, h) a conveyor toguide the films, wherein first film and the second film have differentlengths in cross section, the second film having a first side surfacecomprising a first area of attachment and a second side surfacecomprising a second area of attachment, the first area of attachment andthe second area of attachment to mount the tubular sealing element inthe safing slot, and at least one further conveyor belt or profile toshape the tubular sealing element to have a profile geometry, wherein asealing portion of the profile geometry, in cross section, consists ofone sealing region, wherein the apparatus does not comprise aperforation unit for perforating a connection area.
 12. The apparatusaccording to claim 11, further comprising j) a perforation unit forventing the tubular sealing element, and l) optionally, a cutter to cutthe tubular sealing element to a desired length.
 13. The apparatusaccording to claim 11, wherein at least one of the first feed apparatusand the second feed apparatus comprises at least one roll.
 14. Theapparatus according to claim 11, wherein the conveyor to guide the filmcomprises a conveyor belt having one or more guide elements.
 15. Atubular sealing element produced according to the method according toclaim
 1. 16. A method for fire-, smoke-, sound- and water-proof sealingof perimeter joints in a curtain wall construction, said methodcomprising: applying the tubular sealing element according to claim 15to a safing slot.
 17. A tubular sealing element produced using theapparatus according to claim 11.